Cigarette filling machine tube sensing and positioning apparatus

ABSTRACT

A braking apparatus and a sensing apparatus for locating the position of and for positioning a filling tube holder. The apparatus comprises a movable filling tube holder capable of holding a plurality of filling tubes and a filling tube having a first end, a second end, an inside diameter, and an outside diameter disposed in said filling tube holder. A braking body having a contact portion communicates with the filling tube holder and provides a resistance to the movement of the filling tube holder. Also disclosed is a sensing apparatus that determines the position of a filling tube holder.

FIELD OF INVENTION

This invention relates generally to an apparatus for sensing andpositioning a cigarette filling tube holder. More particularly, thisinvention relates to a braking mechanism for a cigarette filling tubeholder and a sensor to determine the location of a filling tube holder.

BACKGROUND OF THE INVENTION

Prior to the invention of the electronic rolling machine, rolling yourown cigarettes was restricted to manual table top machines, hand heldmachines, and attempts that have been made to perfect personal singlestick electric machines. These machines employ a chamber for loadingtobacco, a manual lever that compresses the tobacco, and a spoonmechanism that injects the tobacco into an empty preassembled cigaretteblank. Many attempts have been made with varying degrees of success toperfect a table top electric machine. These basically employed the sametechnology, only electronically enhanced. The shortcoming is that thespoon mechanism shreds the tobacco. Secondly, loading the proper amountof tobacco each time is extremely variable. The other obvious drawbackis the tedious nature of the process; each cigarette blank must bemounted on a nozzle manually. Moreover, the empty cigarette blanks areextremely fragile and easily damaged during the process.

While other electronic machines for use in retail settings have beendeveloped, there remain drawbacks with those machines. First, separatingthe cigarette blanks for individual loading onto a filling tube remainsimprecise. Secondly, loading the fragile cigarette blanks unto fillingtubes often results in damaged and unusable cigarette blanks.

What is needed is an apparatus and method for separating and loading thecigarette blanks on a machine in a retail setting.

SUMMARY OF THE INVENTION

This invention relates to a braking apparatus for positioning a fillingtube holder of a cigarette filling machine, said apparatus comprising amovable filling tube holder capable of holding a plurality of fillingtubes, a filling tube having a first end, a second end, an insidediameter, and an outside diameter disposed in said filling tube holder,and a braking body having a contact portion communicating with thefilling tube holder and capable of providing a resistance to themovement of the filling tube holder.

This invention also relates to a sensing apparatus for determining theposition of a filling tube holder of a cigarette filling machine, saidapparatus comprising a movable filling tube holder capable of holding aplurality of filling tubes, a filling tube having a first end, a secondend, an inside diameter, and an outside diameter disposed in saidfilling tube holder, and a sensing mechanism communicating with saidfilling tube holder.

This invention further relates to a sensing apparatus for determiningthe position of a filling tube holder of a cigarette filling machine,said apparatus comprising a movable filling tube holder capable ofholding a plurality of filling tubes, a filling tube having a first end,a second end, an inside diameter, and an outside diameter disposed insaid filling tube holder, and a sensing mechanism communicating with thefilling tube.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a cigarette making apparatus of theinvention.

FIG. 2 is a perspective view of a tobacco input hopper of the invention.

FIG. 3A is a section view of a tobacco conveying and compressing deviceof the invention.

FIG. 3B is an enlarged section view of the compressing device of FIG.3A.

FIG. 4A is a perspective view of a filling tube of the invention.

FIG. 4B is a perspective view of another embodiment of the filling tubeof the invention.

FIG. 5A is a perspective view of a guide head and pin of the invention.

FIG. 5B is a perspective view of another embodiment of the guide headand pin of the invention.

FIG. 6A is a section view of the filling tube holding drum of theinvention.

FIG. 6B is a section view of a filling tube mounted in a drum partiallyreceiving a guide head of the invention.

FIG. 6C is a section view of a filling tube mounted in a drum fullyreceiving a guide head of the invention.

FIG. 6D is a section view of a filling tube mounted in a drum fullyreceiving a guide head of the invention showing further a cigaretteblank being forwarded to the filling tube.

FIG. 6E is a section view of a filling tube mounted in a drum fullyreceiving a guide head of the invention showing further a cigaretteblank being fully loaded on the filling tube.

FIG. 6F is a section view of a tobacco plug being injected into acigarette blank loaded onto a filling tube of the invention.

FIG. 6G is a section view of a completed cigarette being ejected from afilling tube of the invention.

FIG. 6H is a section view of an improperly loaded cigarette blank beingejected from a filling tube of the invention.

FIG. 7 is a side view of a cigarette blank loading cartridge of theinvention.

FIG. 8 is a perspective view of a cigarette blank separation device ofthe invention.

FIG. 9 is a section view of a cigarette blank separation device of theinvention having a mounted cigarette blank loading cartridge in thelowered position holding a plurality of cigarette blanks.

FIG. 10 is a section view of a cigarette blank separation device of theinvention having a mounted cigarette blank loading cartridge in theraised position holding a plurality of cigarette blanks.

FIG. 11 is a perspective view of another embodiment of the guide headand pin of the invention.

FIG. 12 is a section view of the guide head and pin of FIG. 11 with aportion of the guide head collapsed and having exited the filling tube.

FIG. 13 is a section view of the guide head and pin of FIG. 11 with aportion of the guide head expanded and having exited the filling tube.

FIG. 14 is a perspective view of a braking apparatus of the invention.

FIG. 15 is a perspective view of another embodiment of the filling tube.

DETAILED DESCRIPTION OF THE INVENTION

A cigarette making apparatus 10 is illustrated in FIG. 1. The apparatus10 includes a tobacco input hopper 100 (rotated upward for clarity), atobacco conveying and compressing device 200, a cigarette blankseparation device 300, a filling tube holder 400, a material and producttransfer mechanism 500, and a discharge container (not shown).

The input hopper 100, illustrated in FIG. 2, has a main body 101 with atobacco inlet 102. The input hopper has a top end 104, a bottom end 105,a first side 106, a second opposing side 107, a discharge end 108, andan input end 109. A conveyor 103 may be mounted in the bottom end 105 ofmain body 101 to convey the tobacco from the input end 109 toward astrand separator 110 mounted generally on the discharge end 108. Theconveyor may include a tension adjustment mechanism 116 for adjustingthe conveyor belt tension. The strand separator 110, having a shaft 111and a plurality of pins or combs 112 extending outwardly therefrom, ismounted on the discharge end 108 of the main body 101. The strandseparator shaft 111 may be rotatably driven by an electric motor 113.Depending on the desired rotational speed of the strand separator 110, aspeed reduction mechanism 114 may be employed to communicate theelectric motor 112 with the strand separator shaft 111.

In operation, cut tobacco is poured into the tobacco inlet 102 of theinput hopper 100. The cut tobacco falls onto the input end 109 of theconveyor 103 and is thereby transferred toward the strand separator 110and discharge end 108 of the conveyor 103. After going through thestrand separator 110, the cut tobacco is discharged from the inputhopper 100 through a discharge opening 115.

FIG. 3A illustrates a tobacco conveying and compressing device 200. Thedevice 200 generally has an input end 201, a receiving hopper 215, and atobacco conveying zone 218. A tobacco conveyor system 210 has a firstconveyor 202 having a top end 203 and a lower end 204 and a secondconveyor 205 having a top end 206 and a lower end 207. The conveyors 202and 205 are mounted between a first side plate 217 and a second plate(not shown). Conveyor 202 has a conveyor belt 208, and conveyor 205 hasa conveyor belt 209. The conveyor belts 208 and 209 may have styrationsor fingers on them, allowing the moving belts to grip the cut tobacco.The top end 203 of the first conveyor 202 and the top end 206 of thesecond conveyor 205 communicate with the receiving hopper 215.Typically, the conveyors 202 and 205 converge on each other as they movein the direction of arrows 211 and 212, respectively. At least oneelectric motor (not shown) may be used to drive the first conveyor 203and second conveyor 205.

In operation, the receiving hopper 215 receives cut tobacco from thedischarge opening 115 of the input hopper 100 described above. As aninward side 213 of conveyor 202 and an inward side 214 of conveyor 205move downward, cut tobacco is received from the receiving hopper 215,compressed by conveyors 202 and 205, and ultimately transferred to acompressor device 250.

The tobacco compressing device 250 illustrated in FIG. 3B has a firstcompression plate 251 and a second compression plate 252, which definegenerally a compression cone 253. The first compression plate 251 isslidably mounted in the tobacco compressing device 250 to allow it tomove toward the second compression plate 252. The first compressionplate 251 has a first end 254 and a second end 255, the second enddefining a semi-circular compression cavity 256 having a top edge 257. Apneumatic cylinder 261 having a piston rod 262 may be mounted to a frame(not shown), with the piston rod 262 of the pneumatic cylinder 261communicating with the first end 254 of the first compression plate 251,thereby slidably operating the first compression plate 251 towards andaway from the second compression plate 252. Other methods may be used toslidably move the first compression plate 251, such as a servo motor ora hydraulic cylinder. The second compression plate 252 has a first end258 and second end 259, the second end 259 defining a semi-circularcompression zone 260. The second compression plate 252 also contains aknife 263 with a cutting edge 264 that is coplanar with the top edge 257of the semicircular compression cavity 256 of the first compressionplate 251 and with a top edge 266 of the semicircular compression cavity260 of the second plate 252. The knife 263 may be mounted so that it isnot parallel to the top edge 257 of the first compression plate 251,resulting in the first plate 251 contacting only one portion of theknife edge 264 at a time as the first plate 251 slidably moves towardsthe second plate 252.

In operation, the downwardly moving inner sides 213 and 214 of conveyors202 and 205, respectively, partially compress cut tobacco and deliver itto the compression cavity 253. The conveyors 202 and 205 run for aperiod of time to deliver an amount of cut tobacco into the compressioncavity 253, and then stop. The amount of tobacco that is delivered intothe compression cavity 253 may be within a predetermined range, with theexact amount being established by the operator of the machine dependingon individual preferences, which may include, among other things, theoperator's preferred “draw” of the cigarette. Then, the piston 261pushes the first compression plate 251, by way of piston rod 262, towardthe second compression plate 252, further compressing the tobacco in thetobacco cavity 253. As the first compression plate 251 moves toward thesecond compression plate 252, the top edge 257 of the first compressionplate 251 meets the cutting edge 264 of the knife 263. The cut tobaccoin the compression cavity 253 is then sheared from the cut tobacco inthe tobacco conveying zone 214. The first compression plate 251continues to move toward the second compression plate 252, therebyforming a tobacco plug 265. The first compression plate 251 thenretreats slightly away from the second compression plate 252, allowing atobacco plug insertion pin 501 (FIG. 1) to push the tobacco plug 265 outof the compression cavity 253 into a filling tube 350 (described later).Typically, the tobacco plug 265 is smaller in diameter than the insidediameter of a filling tube and a cigarette blank to allow for easyinsertion into the filling tube and the cigarette blank.

FIG. 4A illustrates a filling tube 350 having a first end 351, a secondend 352, an inside diameter 353, and an outside diameter 354. Thesetubes are mounted on the filling tube drum 401 shown in FIG. 1. Othershapes of tubes may be used as filling tubes, including square oroctagonal shaped tubes. The first end 351 of the filling tube may have ashoulder 355 for securing the filling tube 350 to a filling tube holder(not shown). Alternatively, a filling tube may be secured to a fillingtube holder (not shown) by other means, such as a press fit or welding.FIG. 4B shows an embodiment of the filling tube 359 without a shoulderthat may be press fit or welded to a filling tube holder (not shown).The inside diameter of the first end 351, may have a taper 358 from thefirst end 351 outside diameter 356 to the inside diameter 353 forreceiving a guide head 370. Also, as shown in the embodiment of FIG. 4B,the second end 356 may be tapered to facilitate the reception thereon ofa cigarette blank.

FIG. 5A illustrates an embodiment of a guide head 370. The guide head370 has a distal end 371 and a proximal end 372 and is sized to fitwithin the inside diameter 353 of the filling tube 350. The proximal end372 of the guide head 370 has fastening means 373 for attaching theguide head 370 to a pin 374 having a complimentary fastening means 375.The fastening means 374 and 375 can be a threaded connection, a pressfit, or other methods known to those of ordinary skill in the art.Additionally, the guide head 370 and the pin 374 may be fabricated forma single piece of material. The distal end 371 of the guide head 370 hasa substantially conical head 376. The largest diameter 377 of theconical head 376 is typically equal to or greater than the outerdiameter 354 of the filling tube 352. Therefore, the conical head 376 iscollapsible to enable it to pass through the filling tube 350 and exitout the second end 352 of the filling tube 350.

Various means may be used to provide a collapsible guide head. In theembodiment 370 shown in FIG. 5A, a plurality longitudinal slots 365 arecut from the tip 378 of the conical head 376 to a slot terminationlocation 367. The slots typically terminate at a radius 366 to reducestresses that the slots may induce into the guide head material andthereby prevent self propagation of the slots toward the proximal end372 of the guide head 370. The guide head 370 may be made from a varietyof materials, including plastics and metals. Typically, one may use ahardened steel, such as 01 steel hardened to 58-60 Rockwell C, for theguide head. Other means, such as a flexible rubber guide head, a polymerguide head, or an inflatable guide head may be used to produce acollapsible guide head.

FIG. 5B illustrates an embodiment of a pin 362 with guide head 363 inwhich the outside diameters of the pin 362 and the guide head 363 areequal to or less then the inside diameter 353 of the filling tube 350.In this embodiment, the guide head 363 does not need to collapse to passthrough the filling tube 350.

Referring to FIG. 6A, there is a filling tube holder 400 comprising adrum 401 having a first end 402 and a second end 403. The first end 402of the drum 401 has a plurality of holes 404 and 405 for receiving aplurality of filling tubes 350. Other holes (not shown) for receivingfilling tubes may also be disposed on the first end 402 of the drum 401.

This description describes filling tube 350 and the features in the drum401 associated with filling tube 350. Other filling tubes mounted in thedrum will typically be mounted in a similar manner, and the drumtypically will have similar features for each of the other fillingtubes. One method of attaching a filling tube 350 to a drum 401 is aclamping device 408 against the shoulder 355 on a first end 351 of thefilling tube 350. Alternatively, other means for attaching the fillingtubes to a filling tube holder may be used. For example, the fillingtubes and the plurality of holes in the holder for receiving the fillingtubes may be threaded. Additionally, other methods instead of a drum maybe used for holding a plurality of tubes, for instance, the fillingtubes may be mounted on a plate or on a belt.

Axially aligned with the filling tube hole 404 is a conical directinghole 411, having a proximal end 412 and a distal end 413. The distal end413 of the cone shaped hole defines the larger diameter of the cone, andthe diameter of the proximal end of the cone shaped hole is slightlylarger than the outside diameter of a cigarette blank (discussed later).

FIG. 6B is a partial section view of the drum 401 having the fillingtube 350 into which the guide head 370, typically attached to a pin 374(not shown), is passing. As the conical head 376 of the guide head 370passes into the first end 351 of the filling tube 350, the filling tube350 squeezes the guide head 370, thereby collapsing guide head 370 andallowing the largest diameter 377 of the guide head 370 to be less thanthe inside diameter 353 of the filling tube 350.

FIG. 6C is a partial section view of the drum 401 having the fillingtube 350 through which the conical head 376 of the guide head 370,typically attached to a pin 374 (not shown), has passed. The conicalhead 376, having passed through the guide tube 350, can be observed inits relaxed state with the large diameter 377 of the guide head 370 nowequal to or greater than the outside diameter 354 of the filling tube350.

FIG. 6D illustrates a cigarette blank being loaded onto the filling tube350. The conical head 376 extends beyond the filling tube 350. A loadingpin (not shown) induces a force on the filter end 426 of a cigaretteblank 425, causing the cigarette blank 425 to move toward the conicalhead 376 of the guide head 370. In this illustration, an open end 427 ofthe cigarette blank 425 has been damaged, resulting in the normalcircular shape of the end of the cigarette blank 425 becoming oblong. Asthe cigarette blank 425 moves toward the guide head 370, the smallerdiameter 412 of the conical hole 411 in the drum 401 will operate toreturn the oblonged open end 427 of the cigarette blank 425 to a morecircular shape. The cigarette blank 425 continues through the conicalhole 411, over the conical head 376, and then onto the filling tube 350.

FIG. 6E is similar to FIG. 6D, with the exception that the cigaretteblank 425 has been fully inserted on the filling tube 350 by a cigaretteblank insertion pin 504 (FIG. 1). Thereafter, the guide head 370 isremoved from the filling tube 350 by withdrawing it out through thefirst end 351 of the filling tube 350. The filling tube 350 andcigarette blank 425 are then ready to receive the tobacco plug 265prepared by the previously discussed compressing device 250.

FIG. 6F is similar to FIG. 6E, with the additional step of removing theguide head (not shown) and inserting the tobacco plug 265. A sensor 601(FIG. 1) determines whether a cigarette blank 425 is present andproperly loaded onto a filling tube 350 before a tobacco plug 265 isinjected into the filling tube 350. After confirming that a filling tube350 is ready to receive a tobacco plug, an injection pin 501 pushes atobacco plug 265 out of the compression chamber and into the fillingtube 350. Thereafter, the injection pin 501 is withdrawn.

FIG. 6G illustrates an ejecting pin 503 (FIG. 1) ejecting a completedcigarette tube 430, having been filled with a tobacco plug 265, from thefilling tube 350. Typically, the ejection pin 503 is hollow, andpressurized air may be introduced into the ejection pin 503 during theejection process. Pressurized air escaping from forward end 511 of theejection pin 503 further facilitates the ejection of the completedcigarette tube 430.

As noted above, the sensor 601 determines whether a cigarette blank isloaded properly onto a filling tube before injecting a tobacco plug intothe filling tube and cigarette tube. If an improperly loaded cigaretteblank is found, the cigarette blank is not injected with a tobacco plugand the improperly loaded cigarette blank continues to rotate on thedrum, eventually arriving at the cigarette tube rejection location. FIG.6H depicts the removal of a rejected cigarette tube from a filling tube.FIG. 6H illustrates a rejection pin 502 forcing a damaged cigaretteblank 428 off of the filling tube 350 toward a collection mechanism 510(FIG. 1). Typically, the rejection pin 502 is hollow, and pressurizedair may be introduced into the rejection pin 502 during the rejectionprocess. Pressurized air escaping from the forward end 511 of rejectionpin 502 further facilitates removal of the cigarette blank 428 byblowing air against the rejected cigarette blank 428. The collectionmechanism 510, such as a vacuum, collects the rejected cigarette blank428.

Referring now to FIG. 7, there is cigarette blank holding cartridge 310having a rectangular-shaped box 321 with first end wall 311, a secondend wall 312, side walls 313 and 314 (not shown) disposed between endwalls 311 and 312, and a top 322. The first end wall 311 has a loweredge 315, to which a cartridge bottom 316 may be pivotably mounted usinga hinge 317 or other similar pivoting mounting means. The first end wall311 has a handle 318. Mounting tab 319, affixed to the bottom 316 of thecartridge 310, is slideably mountable onto a base plate 326 (FIG. 9).Mounting tab 320, affixed to the second end wall 312 at the cartridge310, is receivable into a cartridge tab receiving area 337 (FIG. 9) ofthe cigarette blank separation device 300. Typically, the cartridge 310may hold a plurality of cigarettes, e.g., about 200 cigarette tubes.Typically, the cartridge is of a size so that a user may set an entirecarton of cigarette blanks (200 cigarette blanks) into the cartridgewithout removing the cigarette blanks from the box before loading. Thecartridge may also be of a size to hold a carton of 100 cigaretteblanks. Alternatively, if one desires to use a carton of cigaretteblanks containing less than 200 cigarette blanks in a cartridge designedfor 200 cigarette blanks, than a block may be used to take up the extraspace in the cartridge.

In operation, a user turns the cartridge 310 upside down so that thebottom 316 is on the top, and opens fully the bottom 316. The user thensets a full box of cigarette blanks into the cartridge 310. Thereafter,the user may tear the top from the cigarette carton and close thecartridge bottom 316. The loaded cartridge is then ready for loadinginto the cartridge tube separator device 300.

FIG. 8 illustrates a perspective view of the cigarette blank separationdevice 300 having received cartridge 310. Also visible is the sensingmechanism 601 and the collection mechanism 510 for collecting a rejectedcigarette blank (not shown).

FIG. 9 is a partial section view of the cigarette blank separationdevice 300 having received a cartridge 310 holding a plurality of blankcigarettes 325. The cigarette blank separation device 300 has a baseplate 326 that has a lower end 327, an upper end 328, a first side 330,and an opposing second side. A first side plate 331 is disposed on thefirst side 330 of the base plate, and an opposing second side plate (notshown) is disposed on the opposing second side of the base plate 326.

The mounting and operation of the first side plate 331 will be describedherein, and the mounting and operation of the opposing second side plate(not shown) is substantially similar to that of the first side plate331. A cross bar 336 ties the first side plate 331 to the second sideplate (not shown). The cross bar 336 has a cartridge tab receiving area337 for receiving the mounting tab 320 disposed on the second end wall312 of the cartridge box 321. The first side plate 331 has an upper end332 that is pivotally mounted at a pivot point 338 adjacent to the upperend 328 of the base plate 326. A portion 335 of the first side plate 331rides on an eccentric cam 333 that rotates about a camshaft 334. The camshaft may be driven by a motor (not shown) or by other means availableto impart a rotational action upon the camshaft 334. FIG. 9 depicts thefirst side plate 331 and the cigarette blank loading cartridge 310 in adown position, the position in which a user would insert a cigaretteblank loading cartridge 310 containing a plurality of cigarette blanks.

As the cam 333 rotates about the camshaft 334, the first side plate 331and opposing second side plate (not shown) pivot about pivot point 338,thereby resulting in the lower end 339 of the first side plate 331 andthe lower end of the second side plate moving along an upward arc 340.The cross bar 336, being affixed between the first side plate 331 andthe second side plate, moves upward. The cartridge box 321 also movesupward, because the mounting tab 320 of the cigarette blank loadingcartridge 310 has been received in the cartridge tab receiving area 337of the cross bar 336.

FIG. 10 is a partial section view of the cigarette blank separationdevice 300 with the cartridge box 310, the first side plate 331 and thesecond side plate (not shown) in the elevated position.

The lower end 327 of the base plate 326 abuts a shaking assembly 380. Inone embodiment, the shaking assembly 380 has a shaking plate 381pivotably mounted a top end 383 to a frame 382. The shaking plate 381may be shook by a variety of methods, and one method of shaking theplate is by an eccentric cam 384. In operation, the rotation of theeccentric cam pivots the plate about the top end 383 of the shakingplate 381, thereby shaking a plurality of cigarette blanks 390.Typically, the lower end 385 of the shaking plate 381 is at a sufficientdistance above the base plate 326 to allow a lowest plurality ofcigarette blanks 396 to pass between the base plate 326 and the lowerend 385 of the shaking plate 381.

The plurality of cigarette blanks 390 has a first row 387, a second row388 and upper rows 389. As the shaking plate 381 advances towards theupper end 328 of the base plate 326, because of the rotation of the cam384, the shaking plate 381 pushes the plurality of cigarette blanks 390toward the upper end 328 of the base plate 326. The base plate 326, hasa retainer 391 for maintaining the position of the cigarette blanks oncethey move to the lower end 392 of the retainer 391. By shaking thesecond row 388 and the upper rows 389 of a plurality of cigarettesblanks 390, the shaking plate breaks up the pyramidal structure 393 thatordinarily forms between successive rows of cigarettes. Additionally,the retainer 391 keeps the lower plurality of cigarette blanks 396 frommoving toward the upper end 328 of the base plate 326, furthering theshaker's effectiveness in breaking the pyramidal structure 393.

The cigarette blank loading area 394 has in it a cigarette blank 395ready to be loaded onto a filling tube 350 as depicted in FIG. 6D andFIG. 6E. After a cigarette blank loading pin 504 pushes the cigaretteblank 395 out of the cigarette blank loading area 394, the lowestplurality of cigarette blanks 396 advance forward, moving anothercigarette blank into the cigarette blank loading area 394.

Referring back to FIG. 1, there is the material and product transfermechanism 500 that has on it the tobacco plug injection pin 501, thecompleted cigarette ejection pin 503, and the improperly loadedcigarette blank rejection pin 502. Typically, the pins 501, 502 and 503are linearally moved along their axis by a plurality of pneumaticcylinders (not shown). The injection pin 501 and the pneumatic cylinderassociated therewith is mounted in a slideable fixture 507. The fixture507, slideably mounted in a frame 505, is slideable by a hand crank 506.The slideably mounted injection pin 501 allows for adjustment of the pinto accommodate various lengths of cigarette blanks.

FIG. 1 illustrates the general operation of the cigarette makingapparatus. In operation, a user fills a cigarette blank cartridge with aplurality of cigarette blanks and loads the cartridge 310 into thecigarette blank separation assembly 300. The user also pours tobaccointo the tobacco inlet 102 of the input hopper 100. The user then startsthe operation of the cigarette making apparatus 10. The automaticoperation of the cigarette making apparatus is typically controlled byelectronics such as a computer or a programmable logic controller(“PLC”) (not shown) adapted to interface with the various components ofthe cigarette making apparatus 10.

The cigarette blank separating device 300 separates a cigarette blank395 from the plurality of tubes in the cartridge 310, allowing acigarette blank to flow into the loading area 394 as shown in FIG. 10. Afilling tube 350 with a portion of the guide head 370 extending beyondthe second end 352 of the filling tube 350 (FIG. 6C) mounted on a drum401 is axially aligned with the cigarette blank 395. Thereafter, acigarette blank loading pin 504 pushes the cigarette blank onto thefilling tube 350, and the guide head 370 is withdrawn from the fillingtube 350 (as addressed in the discussion regarding FIG. 6D and FIG. 6E).The drum 401 then indexes forward in the direction shown by arrow 602.

Referring again to FIG. 1, when the filling tube 350 having on it acigarette blank reaches a position 603, a sensor 601 ensures that acigarette blank is loaded properly. If the sensor finds a tube properlyloaded, then an injection rod 501 injects a previously compressedtobacco plug 295 into the filling tube 350 (as discussed above regardingFIG. 6F). If the sensor 601 finds an improperly loaded tube, then thecigarette making apparatus skips the tobacco plug injection process, andthe drum 401 continues to index forward in the direction of arrow 602.

After a tobacco plug is successfully injecting into a filling tube 350having on it a cigarette blank, the drum 401 continues to index forwardin the direction of arrow 602, whereupon the filling tube 350 willarrive at a completed cigarette ejection position 604. Once there, anejection rod 503 will eject the completed cigarette from the fillingtube 350, as shown in FIG. 6G. The completed cigarettes may then fallinto a collection device (not shown), where they may be retrieved by theoperator.

If the sensor 601 has found an improperly loaded cigarette blank, thenthe drum 401 with the filling tube 350 holding the improperly loadedcigarette blank will continue to index forward on in the direction ofarrow 602, skipping the tobacco injection process and the completedcigarette ejection process, whereupon it arrives at an improperly loadedtube rejection area 605. Thereafter, a rejection pin 502 pushes theimproperly loaded cigarette blank off of the filling tube. (FIG. 6H).

After the above discussed process is complete and a completed cigaretteis made (or an improperly loaded cigarette blank is rejected), thefilling tube is ready to receive a new cigarette blank. Typically, theabove discussed process will produce 25 completed cigarettes a minuteswith less than 4 rejected cigarettes per 100 completed.

The plurality of filling tubes on the drum 401 allows the above steps totake place concurrently. For instance, a cigarette blank may be insertedon a filling tube at the same time a tobacco plug is being injected intoanother filling tube, which may be occurring at the same time acompleted cigarette is being rejected from a filling tube, which may beoccurring at the same time an improperly loaded cigarette blank is beingrejected. Additionally, the tobacco conveying and compressing and thecigarette blank separating may also be occurring concurrently with theabove steps.

Another embodiment of a guide head and a pin is shown in FIG. 11. Theexpandable head system 700 comprises a guide head 701, a hollow tube702, a spring shaft 703 having a collar 704, a spring 705, and a body706.

As illustrated in FIG. 12, the body 706 has an internal bore 708 in aforward end 709 for receiving the spring shaft 703. The spring shaft 703is slidably mounted in the internal bore 708 of the body 706. Frictionreduction members 713 and 714 may be disposed in the internal bore 708between the spring shaft 703 and the body 706 to guide the spring shaft703. The spring 705 is disposed on the spring shaft 703, and the springshaft 703 is retained in the internal bore 708 by a stop 735 mounted toa back end 710 of the spring shaft 703. The spring 705 is compressed andis retained between a front face 711 of the body 706 and the collar 704of the spring shaft 703. A washer 712 may be disposed on the springshaft 703 and against the front face 711 of the body 706 for receivingan end 732 of the spring 705.

A first end 720 of the hollow tube 702 is affixed to the collar 704 ofthe spring shaft 703, and a second end 733 of the hollow tube 702receives the guide head 701. An internal bore 719 of the spring shaft703 communicates with a hollow central portion 721 of the hollow tube702. A pin 707 has a first end 715 that is affixed to a back end 718 ofthe body 706. The pin 707 passes through the internal bore 719 of thespring shaft 703, through the hollow tube 702, and terminates in theguide head 701. Friction reduction members 722 and 723 may be disposedin the internal bore 719 of the spring shaft 703 to guide the pin 707.

A second end 724 of the pin 707 terminates in a conical head portion 725of the guide head 701. The conical head portion 725 has a conicalinternal cavity 726 that is sized to receive the second end 724 of thepin 707 when the conical head portion is in a collapsed configurationand further has an internal cavity 727 that is smaller than the secondend 724 of the pin 707. The guide head 701 may have a plurality oflongitudinal slots similar to the embodiment of a guide head shown inFIG. 5A.

FIG. 12 illustrates the conical head portion 725 of the guide head 701having passed through the second end 352 of the filling tube 350 withthe pin 707 in the retracted position. FIG. 12 shows the distal end ofthe expandable head system 700 enlarged to illustrate detail. With thepin 707 in the retracted position, the conical head is collapsed,whereby a large diameter 728 of the conical head portion 725 is equal toor smaller in diameter than the inside diameter 353 of the filling tube350. The expansive forces of the spring 705 maintain the pin in theretracted position and maintain the position of the guide head 701relative to the pin 707 until a force sufficient to overcome theexpansive spring force is induced on the pin 707.

FIG. 13 illustrates the conical head portion 725 of the guide head 701having passed through the second end 352 of the filling tube 350 withthe pin 707 in the extended position. FIG. 13 shows the distal end ofthe expandable head system 700 enlarged to illustrate detail. With thepin 707 in the extended position, the second end 724 of the pin 707 haspassed into the internal cavity 727 of the conical head portion 725,thereby expanding the conical head portion 725 to a diameter 729 that istypically greater than the inside diameter 353 of the filling tube 350,and more typically is greater than the outside diameter 354 of thefilling tube 350. In that position, the conical head portion 725 ispositioned to receive and guide a cigarette blank onto the filling tube.

In operation, the guide head 701 is passed through the filling tubeuntil the conical head portion 725 passes through the second end 352 ofthe filling tube 350, at which time means for stopping the spring shaft703 acts to stop the forward movement of the spring shaft 703, thehollow tube 702, and the guide head 701. Thereafter, the body 706continues to move forward a distance 730 to extend the second end 724 ofthe pin 707 into the internal cavity 727 of the conical head portion725, thereby expanding the conical head portion 725 of the guide head701. A cigarette blank may then be inserted over the conical headportion 725 and onto the filling tube 350. The body 706 is thenretracted, thereby retracting the second end 724 of the pin 707 from theinternal cavity 727 and allowing the conical head portion 725 to returnto its collapsed configuration. The retraction of the body 706continues, extracting the tube 702 and the guide head 701 from thefilling tube 350.

Other types of filling tubes may also be used. FIG. 15 illustrates afilling tube 849 having a hollow cylindrical portion 851 and a hollowtapered portion 852. The cylindrical portion 851 has an inside diameter853, an outside diameter 854, a first end 860, and a second end 861. Thetapered portion 852 has a first end 862 with an outside diameter 863 anda second end 864 with an outside diameter 865. The outside diameter 865of the second end 864 of the tapered portion 852 is typically less thanthe outside diameter 863 of the first end 862. The outside diameter 854of the cylindrical portion 851 is substantially the same as the outsidediameter 863 of the first end 862 of the tapered portion 852, therebycreating a smooth transition from the cylindrical portion 851 to thetapered portion 852 where the first end 862 of the tapered portion 852adjoins the second end 861 of the cylindrical portion 851. The outsidediameter 863 of the tapered portion 852 is sized to receive a tobaccoblank (not shown).

The second end 864 outside diameter 865 of the tapered portion 852 isless than the outside diameter 854 of the cylindrical portion 851 toguide a cigarette blank (not shown) onto the larger cylindrical portion851. A tobacco plug (not shown) enters the filling tube 849 through thefirst end 860 of the cylindrical portion 851, and moves forward into thetapered portion 852, which is constructed of metal, plastic or othermaterials that are sufficiently flexible to expand and contract. Thetobacco plug has an outside diameter that is slightly smaller than theinside diameter 853 of the cylindrical portion 851. Thus, when thetobacco plug is inserted into the filling tube 849, it expands theflexible tapered portion 852 so that the second end 864 of the flexibletapered portion 852 has an outside diameter 865 approximately the sameas the outside diameter 854 of the cylindrical portion 851. When acompleted cigarette (not shown) is removed from the filing tube, theoutside diameter 865 of the second end 864 returns to its initialsmaller diameter. In one embodiment, the tapered portion 852 contains aplurality of flexible fingers 870 that are biased inward at the secondend 864, thereby forming an outside diameter 865. The plurality offlexible fingers 870 also define a plurality of longitudinal slots 872.The longitudinal slots have a radius 874 at about the first end of thetapered portion 852 to prevent the slots from unintentionally radiatingtowards and cracking the cylindrical portion 851 of the filling tube849. The filling tube 849 may have a shoulder 855 for securing thefilling tube to a filling tube holder.

FIG. 1 further depicts a braking apparatus 800 for positioning thefilling tube holder 400. Typically, the braking apparatus provides aresistance to the rotation in the direction of arrow 602 and in thedirection opposite arrow 602 of the filling tube holder 400. Typically,the resistance is a result of contact between a contact portion 808 ofthe braking apparatus and the filling tube holder at the contact area814.

Means for indexing the filling tube holder 400 forward, in the directionof arrow 602, include a pneumatic, mechanical, electromechanical, orother system (not shown) that will rotate the filling tube holder. Onesystem that may be used to index the filling tube holder 400 forward inthe direction of arrow 602 is a pneumatic indexer.

The indexing means and the indexing system connecting the indexing meansto the filling tube holder may have some free play inherent in theiroperation, thereby allowing the filling tube holder to rotate back andforth slightly after the indexing operation is completed. The free playof the indexing means, the indexing system and the filling tube holdermay lead to misalignment among the filling tubes and other parts of thecigarette filling machine such as the tobacco insertion pin 501, theguide head 370, the cigarette blank loading pin, the ejection pin 503,or the rejection pin 502. A braking apparatus can reduce the free play.

As shown in FIG. 14, the braking apparatus 800 has a body 806. The bodyincludes connecting portions 816 and 818 for connecting the body to thecigarette making apparatus 10. Fasteners, such as fasteners 804 shown inFIG. 1, may be used to connect the body 806 to the cigarette makingapparatus. Other methods of connecting the body to the cigarette makingapparatus, such as welding, may also be used. The braking apparatus maybe fabricated from metal, plastic, or other suitable material.

Referring back to FIG. 14, the body 806 also includes the contactportion 808 which contacts the filling tube holder 400 to provideresistance to the movement of the filling tube holder. Additionally, thecontact portion may further include a friction pad 812 that contacts thefilling tube holder. The friction pad may be cork, rubber, metal,ceramic, or other material that causes a resistance to movement of thefilling tube holder. Additionally, the friction pad may be a materialthat increases the resistance to movement of the filling tube holder, orit may be a material that decreases the resistance to movement of thefilling tube holder.

The body 806 may also include a spring 810 that biases the contactportion 808 of the body 806 against the filling tube holder. The amountof movement resistance the braking apparatus imparts on the filling tubeholder is a function of the coefficient of friction between the contactportion of the body and the filling tube holder and the amount of forcepushing the contact portion against the filling tube holder. Typically,a spring imparts that force, but other means such as a pneumaticcylinder may also impart that force. In FIG. 14, the spring 810 isintegral with the body 806. Alternatively, other springs, such as a coilspring or flat spring pushing the contact portion 808 against thefilling tube holder, may also be used.

The body 806 may include an engagement mechanism that meshes with amating engagement mechanism on the filling tube holder. For example, thefilling tube holder may include a predetermined number of teeth or cogsdisposed circumferentially around the filling tube holder that mate withcorresponding teeth or cogs on the contact portion 808 of the fillingtube holder. The predetermined number of teeth on the filling tubeholder defines a predetermined number of locations at which the fillingtube holder may be restrained from movement by the braking apparatus. Inthis example, the free play movement of the filling tube holder isrestrained by the intermeshing of the teeth or cogs of the filling tubeholder with the teeth or cogs of the engagement mechanism on the brakingapparatus. Other intermeshing systems may also be used to restrain themovement of the filling tube holder.

FIG. 1 further depicts a sensing apparatus 802 for sensing the positionof the filling tube holder 400. As an indexer moves the filling tubeholder forward in the direction of arrow 602, it is desirous to stop themovement of the filling tube holder when it reaches a position where thefilling tubes align with corresponding components such as the tobaccoinsertion pin 501, the guide head 370, the cigarette blank loading pin,the ejection pin 503, or the rejection pin 502. A sensing apparatus 802is one method of determining the position of the filling tube holder400.

The sensor apparatus 802 may provide a feedback to a system controllingthe indexer to indicate to the control system when the filling tubeholder 400 is correctly positioned. The control system may then stopindexing the filling tube holder 400. The sensor may sense the positionof the filling tube holder 400, it may sense the position of one of aplurality of filling tubes 350, or it may sense the position of a partof the filling tube holder corresponding to a location of the fillingtube holder. The sensor apparatus may be a proximity sensor, or it maybe another sensor capable of sensing the position of the filling tubeholder, a filling tube, or a part on the filling tube holder.

While the present invention has been illustrated by the description ofembodiments thereof, and while the embodiments have been described inconsiderable detail, it is not intended to restrict or in any way limitthe scope of the appended claims to such detail. Additional advantagesand modifications will be readily apparent to those skilled in the art.The invention is therefore not limited to the specific details,representative apparatus and method, and illustrated examples shown anddescribed. Accordingly, departures may be made from such details withoutdeparting from the scope or spirit of the invention.

1. A braking apparatus for positioning a filling tube holder of acigarette filling machine, said apparatus comprising: a movable fillingtube holder capable of holding a plurality of filling tubes, a fillingtube having a first end, a second end, an inside diameter, and anoutside diameter disposed in said filling tube holder, and a brakingbody having a contact portion communicating with the filling tube holderand capable of providing a resistance to the movement of the fillingtube holder.
 2. The braking apparatus according to claim 1, wherein saidcontact portion further comprises a friction pad.
 3. The brakingapparatus according to claim 1, wherein the braking body furthercomprises a spring, wherein the spring applies a force to push thecontact portion against the filling tube holder.
 4. The brakingapparatus according to claim 2, wherein the position of the friction padof the contact portion of the braking body changes relative to thefilling tube holder during operational rotation of the filling tubeholder.
 5. The braking apparatus according to claim 1, wherein saidbraking body further comprises an engagement mechanism wherein theengagement mechanism locates the filling tube holder at any one of aplurality of predetermined positions.
 6. A sensing apparatus fordetermining the position of a filling tube holder of a cigarette fillingmachine, said apparatus comprising: a movable filling tube holdercapable of holding a plurality of filling tubes, a filling tube having afirst end, a second end, an inside diameter, and an outside diameterdisposed in said filling tube holder, and a sensing mechanismcommunicating with said filling tube holder.
 7. The sensing apparatusaccording to claim 6, wherein said sensing mechanism further comprises aproximity sensor.
 8. The sensing apparatus according to claim 6, whereina signal from the sensing mechanism indicates the position of thefilling tube holder.
 9. A sensing apparatus for determining the positionof a filling tube holder of a cigarette filling machine, said apparatuscomprising: a movable filling tube holder capable of holding a pluralityof filling tubes, a filling tube having a first end, a second end, aninside diameter, and an outside diameter disposed in said filling tubeholder, and a sensing mechanism communicating with the filling tube. 10.The sensing apparatus according to claim 9, wherein said sensingmechanism further comprises a proximity sensor.
 11. The sensingapparatus according to claim 9, wherein a signal from the sensingmechanism indicates the position of the filling tube holder.